How do I Measure Acid Level in Auto Batteries

One of my batteries has a stripe on the side that shows green when electrolyte level is correct another has cell cover with indicator too...

ultrasonic non contact acid level checkers are available. contact CMW ,germany or CEMT, china.

Hello Metman,

Can I assume each battery needs a specific amount of acid?

Can you not put a measured amount of say 1 Litre into each battery?

(I am assuming the batteries are filled from a overhead source or a pump)?

Hello Babybear,

I thank you for your answer, Yes we do inject a specific amount. But that is indeed the purpose of the entire excercise, to establish CmK of the Machine doing the injecting. We are trying to ascertain Machine capability Factor via some efficient measuring method. I see I have been advised to check German & Chinese source for sensors My thanks to that quarter too.

Have a grand day all

Best Regards,

Metman

Hello Metman,

I appreciate your reply post, thanks.

Another way to put the right amount of acid in...................... after finding the ccm (Cubic Centimetre) content, is by filling a new battery plastic shell with water, and either pouring the water out into a measure, or weighing the plastic case before and after the water in poured to the desired level, and deducting the weight of the case from the 'full' battery case will give the weight of water needed for that case.

1 CC of pure water at 4°C is one gram .

Sulfuric acid at 95% concentration weighs 1.8 times more than water, so 1 CC will weigh 1.8 grams.

Keep a model of each battery case as a 'file copy'. As you know water creates heat if mixed with sulfuric acid, (if that is what you use in your batteries), so of course you cannot fill the case you may use as a measure which may have water in it.

Sulfuric acid at 95% concentration weighs 1.8 times more than water, so 1 CC will weigh 1.8 grams. You should know the weight of water and acid at the 95% strength used in most batteries, by heart really. Adjust the amount of acid to match the weight of water.

As long as you keep a list of battery sizes and their equivalent of acid needed, and the filling machine/pump is well maintained, the same amount of liquid should be in each case.

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On testing batteries throughout the manufacturing process...

If the case is semi-transparent, and you have a visual mark to fill to, you can use a bright lamp behind the case and it will show the level.

If the case is not translucent then use the weight method to test for acid amount.

We have used this weighing method in Europe to fill and pack cleaning products and tooth paste, on a small scale, and it works pretty well.

Keep in touch

Please let me know what you think, even if you do not like my ideas, OK? I can then look or suggest other solutions. I know the above weighing method works as I have used it for years!

Hey BB, An ethical pleasure.

My sincere thanks to you for your time and comprehensive input, off to give it a try. will be in touch soonest. Our Procurement also looking at sensor sources in the meantime.. Quite an excercise this, with many battery types involved, only a few being "Translucent" the majority Jet Black with no hope of visual assist being employed. Glad to hear of your previous successes using this methodology

Best Regards,

M

Hello Metman,

Many thanks for your kind reply.

I would think a 'hand-off' measurement would work better if you wanted the filler to test as it fills. And I can imagine the more than several different sizes of case you make. I used to deliver to a battery manufacturer and they always seemed to have a different size and or sort of battery case to re-jig the machinery to fit.

My other thought is to have two thin, Depth Guages, with one 3/5 mm longer than the other. Fill the battery so the longest probe is only just under the acid surface, but not so full as to touch the second shortest probe. This will be on the filler or, will be inserted further down the line to test the level. It will not be a 'hands off' approach, but I have not looked at that yet for this purpose.

I have seen all kinds of measuring devices in the past on this site, here is a page to be looking at:

http://www.google.com/search?client=safari&rls=en-us&q=liquid+measuring+from+a+distance&ie=UTF-8&oe=UTF-8

Hey Helloooo Babybear Hope you dont think I'm lost, or forsaken you ... sorry for delay, awfully busy presently as I'm sure you are too. Nothing concrete to report to you as yet. We are still phaffing around here with all sorts of solutions to the problem being tried and tested ... Promise to get back to you asap as soon as I have something worthwhile to give you.

Best Regards,

M

Hello Metman,

Hope it all works out fine in the end!

No problems with when or how often you can reply to me.. Just get stuck into the 'remedies' and let me know when you have found one that is right for you and that works, OK?.................... Seriously, I am no one. Get back when you are ready only, no probs.

Use a device to measure "wall thickness" at the side of the battery case. In each cell there will be an "apparent" change in thickness that will correlate to the surface of the acid.

Mostly these are ultrasonic devices, but in this situation would not be contacting the acid, do not rely on "transparency" of the battery case and could very easily be calibrated for "go/nogo" discrimination based on "Z" height.